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927-0754 3406 (Spec A) Repiaces 8-84 Bose) Psedllsa Onon Service Manual CCK CCKA CCKB Engines Safety Precautions {tis recommended that you road your engine manual and ‘become thoroughly acquainted with your equipment be- fore you start te engine. ‘This symbol is used throughout this ranual to wern of possibve serious eraonal inary. [eaUTION | Thissymbotreferstopossibleoquip- ment damage. Fuels, electrical equipment, batteries, exhaust gases and ‘moving parts present potential hazards that could result in ‘serious, personal injury. Take care in following these . recommended procedures. ” Salety Codes ‘© All focal, state and federal codes should be consulted ‘and compiiad with. ‘© This engine is not designed or intended for use in ireraft. Any such use is at the owner's sole risk. Generat * Provide appropriate fire extinguishers and install them inconvenient ocations. Use an extinguisherrated ABC. by NFPA, (* Make sure that all fasteners on the engine aro secure land accurately torqued. Keep guards in position over tans, riving bets, etc. ‘© Mitis necessary tomake adjustments while the engine is running, use extreme caution when close to hot 6x hhausts, moving parts, ete. Protect Agsinat Moving Parts '* Do not woar loose clothing in the vicinity of moving parts, such as PTO shefts, flywheels, blowers, coup lings, fans, belts, etc. (© Keep your hands away trom moving parts. Batteries ‘© Before starting work on the engine. disconnect batter- {esto prevent inadvertent starting of the engine. '* DO NOT SMOKE while servicing batteries. Lead acid batteries give off ahighly explosive hydrogen gas which ‘can be ignited by lame, electrical arcing orby smoking. ‘Verify battery potarity before connecting battery cables. Connect negative cabie last. Fuel System © DONOT fil fuel tanks while engine is running. ‘* DONOT smoke or use an open flame in the vicinity of ‘the engine or fuel tank. Internal combustion engine fuels are highly flammable. ‘Fuel tines must be ot steel piping, adequately secured, and tree from leaks. Piping at the engine should be approved flexible line. Do not use copper piping for flexible lines as copper wil work harden and become brittle enough to break. ‘© Bo sure all fuel supplies have 2 positive shutoft valve Exhaust System © Exhaust products of any internal combustion en: are toxic and'can cause Injury, or death if inhaled. Alt ‘engine applications, especially those within a confined ‘area, should be equipped with en exhaust system to ‘discharge gases to the outside atmosphere. ‘© Donotuse exhaust gases to heat « compartment. Ensure that exhaust manifolds are secure and are not ‘warped by bolts unevenly torqued. Exhaust Gaa is Deadly! Exhaust gases contain carbon monoxide, 8 poisonous gas that might cause unconsciousness and death. It is an ‘odorless and colorless gas formed during combustion of hydrocarbon fuels. Symptoms of carbon monoxide pol- soning are: «© Dizziness * Headache * Weakness and Sleepiness + Voriting '¢ Muscular Twitching { Throobing in Temples you experience any of netesymotoms, gotoutintofresh airimmetiately, shut down the unit end do not use unit has been inspected. ‘Tho best protection against carbon monoxide inhalation is ‘Proper installation and regular, frequent inspections of the ‘complete exhaust system. If you notico a change in the ‘sound or appearance of exhaust system, shutthe unit down immediately and haveitinspected and repairedatonce bya ‘competent mechani ‘Cooling System © Coolants under pressure have @ higher boiling point than water, D0 NOT open aradiator pressure cap when, ‘coolant temperature is above 212°F (100°C) or white fongine is running. Keep the Unit and Surrounding Area Clean ¢ Make sure that oily rags are not left on or near the engine, ‘© Remove all unnecessary grease and oil froma the unit. ‘Accumulated grease and oil can cause overheating and subsequent engine damage and presenta potential fire hazard. Ee Table of Contents INCORRECT SERVICE OR REPLACEMENT OF PARTS MIGHT RESULT IN ‘SEVERE PERSONAL INJURY AND/OR EQUIPMENT DAMAGE. SERVICE PERSONNEL MUST BE QUALIFIED TO PERFORM ELECTRICAL AND/OR MECHANICAL SERVICE, General Information INTRODUCTION ‘This manual deals with specific mechanical and elec- trical information needed by engine mechanics for troubleshooting, servicing, repairing, or overhauling the engine. Use the table of contents for a quick reference to the separate engine system sections. ‘The troubleshooting guide is provided as a quick ‘reference for locating and correcting engine trouble. The illustrations and procedures presented in each section apply to the engines listed on the cover. The flywheel end of the engine is the front end so right and left sides are determined by viewing the engine from the front. ‘The disassembly section contains major overhaul procedures for stop by step removal, disassembly, inspection, repair and assembly of the engine components. fa major repair or an overhaul is necessary, compe- tent mechanic should either do the job or supervise and check the work of the mechanic assigned to do ‘the job to ensure that all dimensions, clearances and ‘torque values are within the specified tolerances. A parts catalog (available atthe dealer level) contains detailed exploded views of each assembly and the Individual piece part numbers and their propernames for ordering replacement parts. Use only Genuine Onan replacement parts to ensure quality and the best possibie repair and overhaul results. When ordering parts, always use the com- plete Model and Spec number as well as the Serial ‘number shown on the namepiate. ENGINE MODEL REFERENCE Identity your model by referring to the MODEL and SPEC (specification) NO. as shown on the unit nameplate. Always use this number and the engine serial number when making reference to your engine. How tointerpret MODEL and SPEC NO. on generator set engines. $9 CCK -3C R/4 TT TTT Indicates kilowatt rating. ‘Series identification. Voltage code of the generator. Method of starting: A-automat ric starting, and E-electric starting. Factory code for designating optional equipment, itany. Specification letter which advances when thefac- tory makes production modifications. Reremoteelect- om BEN How tainterpret MODEL and SPEC NO. on industrial ‘engines, ae el 2 3 4 1 1. Factory code for general identification purposes. 2. Specific Type: ‘MS-ELECTRIC starting with stub shaft, starter ‘and generator. 3. Factory code for optional equipment supplied, 4. Specification (Spec Letter) advances with factory Production modification. Specifications ‘This manual contains $1 metric equivatents that follow immediately in parentheses after the U.S. customary units of meacure. pena SERIES. SPECIFICATION MEASURE SOK CCKA SCKB Number of Cylinders 2 2 2 Bore in 3.250 3.250 3.250 (om) (62.55) (0255) (82.55) ‘Stroke in 3.000 ‘3,000 3.000 (com) (762) 762) (762) Displacement cuin 49.8 49.8 498 (om?) (216) (816) 16) ‘Compression Ratio 85 t01 7.0104 7.6 tot Riated Speed (Maximum) RPM 2700, 3600 3800 Powerat ‘BHP 129 165 200 Rated Speed (ew) (26) 02.3) 149) ‘Oil Filter Full Flow Full Flow Full Flow it at 30 30 35 (itre) (28) (2.8/0 3) ‘lf Capacity with at 35 35 40 Filter Change (itre) 3.3) (3.3) 88) ‘Crankshaft Rotation (viewed from flywheel) Clockwise Clockwise __Clockwise Governor Mechanical Mechanical Mechanical Valve Clearance (Cold) Intake in 0.007 0.007 0.007 (com) (0.18) (0:18), (0.18) Exhaust in 0.016 0.016 0.016 (mm) (0.41) (0.43) (0.41) Spark Plug Gap (Gas) in 0.018 0.018 0018 (rom) (0.457) (0.457) (0.457) Spark Plug Gap (Gasoline) in 0.025 0.025 0.025 (ron) (0.84) (0.84) (0.64) Breaker Point Gap - Static ia 0.020 0.020 0.020 (Ful Separation and Engine Cold) (mm) (051) (051) (051) Ignition Timing ‘All Models BTC 19 Gaseous Fuel BTC _ : Gest are ey Gasoline Fust (Static) ATC ro eo Gasoline Fue (Stalic or Running) BTC 20°3 2020 Gasoline Fuel Running BTC 24°08 2420 (© - Aad 05 quart (0.47 litre} for eletrc star moda. © - Magneto ignition (© -Magnoto Ignition with Spark Advance Dimensions and Clearances [All clearances given at room temperature of 70°F (21°C). All dimensions in inches (approximate milimetre dimensions in parentheses) unless otherwise DESCRIPTION MINIMUM (MAXIMUM Inches (mm) Inches {mm) CYLINDER BLOCK Cylinder Bore Honed Diameter. 32490 (€2.525) 3.2500 (82550) Maximum Allowable Taper. 0005 (0.127) ‘Outofound 002 (0.051) Main Bearing Inside (Without bearing) 2187 (55.55) 2188 (5558) ‘Main Bearing Inside Diameter CCK (Installed) 20020 (5085) 2.0080 (6088) ‘Main Bearing Inside Diameter CCKA/CCKE (Installed) 20015 (5084) 2.0040 (50.90) ‘Camshaft Bearing Bore (Bearing installed) . 13760 (94.95) 1.3770 (84.98) (CRANKSHAFT Main Bearing Journal Diameter. (60.78) 2.0000 (60.80) Main Bearing Clearance (a064) 0.0038 (0.097) Connecting Rod Journal Diameter. 1.6252 (41.28) 1.8260 (41.30) Crankshaft End Play . 0.006 (0182) 0.012 (0.305) CONNECTING ROD Large Bore Diameter (Without bearing installed ‘and rod bolts property torqued) ....... (4446) 1.7510 (44.48) Connecting Rod Side Clearance (0051) 0.0160 (0.406) Piston Pin Bushing Bore (Without bearing) (ost) 0.8125 (2084) Piston Pin Bushing Bore with Bearing, (Finished bore) .. (1905) 0.7508 (18.07) ‘Bearing to Crankshaft Clearance Nodular tron Rod (0013) 0.0023 (0.056) Aluminum Rod (0051) 0.0038 (0.084) CAMSHAFT Bearing Journal Diameter .. 13740 (9490) 13745 491) Bearing Clearance 00015 (0.038) 0.0080 (0.076) End Play... 00030 (0.076) 0.0120 (0.305) Camshaft Lift 0.300 (7.62) PISTON Clearance in Cylinder ‘Measure 90° to pin 0.10 inch below oil ring (0064) 0.0045 (0.174) Giearance in Cylinder (CCKB with 112-0073, Measure 90° to pin 0.10 inch below oil ring . 00060 (0150) 0.0080 (0.200) Piston Pin Bore (19055) 0.7508 (19.065) Ring Groove Width Top 1 Compression Ring 10960 (2.438) 0.0970 (2.484) No. 2 Compression Ring 00855 (2426) 0.0065 (2.451) No. 3 Oi Contro! Ring 0188 (4775) 0.189 (4.801) DESCRIPTION PISTON PIN ‘Clearance in Piston Clearance in Connecting Rod Diameter Top Groove. Ring End Gap in Cylinder . INTAKE VALVE ‘Stem Diameter ...... Clearance (Stem to Guide) .... Valve Face Angle .... INTAKE VALVE SEAT Valve Seat Wicth Valve Seat Angle ... EXHAUST VALVE ‘Stem Diameter . Clearance (Stem to Guide) Valve Face Angle ... EXHAUST VALVE SEAT ‘Seat Cylinder Head Bore Diameter. ‘Seat Outside Diameter . . Valve Seat With Valve Seat Angie VALVE GUIDE Inside Diameter . TAPPET Body Diameter .......000sesereeerees Bore Diameter... Clearance in Bore « i VALVE SPRINGS INTAKE AND EXHAUST Valve Spring Free Length (Approx). Valve Spring Length Valve Open . Valve Closed .....-. Spring Load @ 1.375 inch (Valve Closed) ‘Spring Load @ 1.125 inch (Valve Open) (GEAR BACKLASH Timing Gear il Pump Gear MINEMUM inches (mm) Inches Thum Push Fit 0002 (0.005) 00007 0.7500 (19.05) 0.7502 0.002 (0.051) 0.008 agro (0254) 0.00 (6.70) 03430 (0025) 0025 ae 0.031 (0.787) 0.047 ae asso @s6t) Oats 0.0025 (0.064) 0.004 ie 1.4890 (30.20) 1.1900 1.1920 (30.28) 1.1930 0.031 (0.787) 0047 i 0.344 (8.74) 0348 O.7475 (18.99) 0.7480, 07505 (1908) 07515 0.0015 (0.038) 0.008 1.662 (42.21) 1.125' (28.58) 1.375 (34.93) 38%. (17 kg) 42 tb, Ti G2kg) 7316 0.002 (0.051) 0.003 0.002 (0.051) 0.005 (mm) (0.018) (19.06) (0.208) (0.508) (e71) (0.064) (1.194) (6674) (0.102) (3023) (30.30) (1.194) (879) (19.00) (19.09) (0.076) (19 kg) (86 kg) (0.076) (x27) Assembly Torques ‘The torque values given in Table 1 have been deter- ‘mined for the specific applications. Standard torque values must not be used where those listedin Tablet apply. The engine assembly torques given here will assute proper tightness without danger of stripping threads. Allthreads must be clean and lubricated with new engine oil before torquing Check all studs, nuts, and capscrews, and tighten as ‘required to keep them from working loose. Refer to the PARTS MANUAL for the location of washers and capscrews. Special Tools TABLE 1. DESCRIPTION Cylinder Head Capscrews .... Rear Bearing Plate... Connecting Rod Bolt lon Rod ..... Aluminum Rod Flywheel Capscrew Starter Mounting Bracket to Oil Base Screws Gear Case Cover «222.012 Oil Pump. Intake Manifold TORQUE SPECIFICATION Ft-Lb. Nm 29-31 (69-42) 20-28 (27-34) 27-29 (7-39) 24-26 (33-35) 35-40 (48-54) 25-35 (84-47) 10-13 (14-18) 7-8 (10-12) 15-20 (20-27) 14-17 (19-23) 43-48 (68-65) ‘The following special tools are available from Onan. Far further information see TOOL CATALOG 900-0078. Vaive Seat Driver Valve Guide Driver (i Guide arid Driver Combination Bearing Remover (Main and Cam) Combination Bearing Driver (Main and Cam) Fiywheet Pulter Engine Troubleshooting GASOLINE ENGINE TROUBLESHOOTING GUIDE, CAUSE “Sanrne eE ass 9 Carded ata Conese Pay serie GEL tourer Fw ner papiee Soe SIFUEL srsten Oat fes Ghar hiv rattense s Soe fae ee te Sia Ar Clem Si Fos ie WTeANAL Enewle” Vals Vee Sen la on Bean Clea COOLING SYSTEM (AIR COOLED) Blown Head Gasket 7) “cootins sysrey waren cooLeo) Seon Ba Lige aE Sirus ay Grunov Tce ano Gover ag Won 2 Dace ants ony Seite te Gee tia Be Starting PRE-STARTING Preparations for the initial and each additional star- ting operation should inciude careful checks of the Oil, fuel, cooling, and electrical systems. The cylinder air housing door should be closed with ali airshrouds in place. Crankcase Oit: Be sure the crankcase has been filled with oll to the "FULL" mark on the oil level indicator, Figure 1. Use oil with the API (American Petroleum Institute) designation SE or SE/CC. Do not use an oil with the designation CD unless itis also designated SE and the oil manufacturer certifies it will perform satisfactorily in gasoline engines. For gaseous operation, use an ashless or low-ash detergent oil specifically made for gaseous- engines. OIL CAPACITIES Electric Start ‘3-1/2 ats. (3.31 litre) 4 gts. (3.8 litre with filter) ‘Manual Start Sts, (28 litre) 3-1/2 ats. (3.3 litre with fitter) Engine oil shouid always be drained when the engine is warm. Remove pipe plug to drain engine oil. Recommended Fuel: Use clean, fresh, regular grade, automotive gasoline. Do not use highly-ieaded Premium types. For new engines, the most satisfactory results are obtained by using nonleaded gasoline. For older ‘engines that have previously used leaded gasoline, ‘heads mustbe taken off and all lead deposits removed ‘from engine before switching to nonleaded gasoline. Mf lead deposits are not removed trom engine before switching from leaded to nonleaded gasoline, pre-ignition could ‘occur causing severe damage to the engine. WARNING ) Spilled fue! might ignite and cause serious personal injury or death. Never flli the tue! tank when the engine is running. Open the fuel line valve (when used) and operate primer to assure fuel supply after filling an empty tank. AP AND on LEVEL INDICATOR: KEEP om, aT Tes LeveL_____. NEVER OPERATE ENGINE WITH OIL BELOW THIS LEVEL. ALWAYS REPLACE CAP TIGHTLY, OR OWL LEAKAGE MAY ‘occur. FIGURE 1. OIL LEVEL INDICATOR WARNING} Grankease pressure could blow out hot oil and cause serious burns. Do NOT check oil while the engine is operating. STARTING Electric Start 1. Move the 2. Push the START button to crank the engine. Manual Start 1. Engine priming before starting is shown in Figure 5 (manual start only). 2, Pl the choke controtabout 3/4 of the way closed or as necessary according to temperature con- ditions. 3, Pull the startrope with a fas, steady pull fo crank ‘the engine. Do not jerk or let rope snap back under its own power. 4. As the engine warms up, adjust the choke gradually to its fully open position. APPLYING LOAD Apply ioad to a new or reconditioned engine gradual- ly in about four steps; not less than 30 minutes funning time for each step. Start with 1/4 lozd, then 172, 9/4 and full-load. ‘STOPPING THE ENGINE ‘When possible, disconnect all load before stopping the engine. Engines equipped with battery ignition are stopped by setting the ignition switch to the off position. Engines equipped with magneto ignition are stopped by pushing the stop button (located on the blower housing). Hold in untii engine completely stops.